Lightweight Vehicle Beam With Multi-Sided Central Beads
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Solution Overview
Problem
Existing vehicle beams face challenges in reducing weight while maintaining strength and energy absorption capabilities, particularly in bending resistance and crush load absorption, due to the complexity and cost of manufacturing irregularly shaped brackets and receptacles for beams with more than four sides.
Innovation Solution
The development of vehicle beams with regularly shaped four-sided end portions and a central portion with more than four sides, where the central portion is formed with beads to enhance strength, using a tailor welded blank with varying thicknesses and manufacturing processes like discontinuous roll forming, allowing for improved crush and bending resistance without the need for complex bracket designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If beams with more than four sides are used to improve bending strength and crush resistance, then strength and energy absorption are improved, but manufacturing complexity and cost increase due to irregular shaped brackets and receptacles
Solution Approach 1:
The beam is divided into a central portion with more than four sides (for strength) and end portions with four sides (for easy connection). This segmentation allows the beam to achieve enhanced bending and crush resistance in the central region while maintaining compatibility with conventional four-sided connection structures, thereby reducing manufacturing complexity of brackets and receptacles.
Solution Approach 2:
The beam employs different cross-sectional geometries at different locations: the central portion has a multi-sided cross-section (12-20 sides) to maximize strength and energy absorption where needed, while the end portions have a four-sided cross-section to simplify connection to frame members. This local differentiation optimizes both strength performance and manufacturing ease.
2Strength
If material thickness is increased to improve strength and energy absorption, then beam strength and crush load capacity are improved, but vehicle weight increases reducing fuel economy
Solution Approach 1:
The beam uses varying material thickness distributed strategically: thicker material at the ends for connection strength and thinner material in the central portion where the multi-sided geometry provides enhanced structural efficiency. This local differentiation allows weight reduction while maintaining overall strength and energy absorption capabilities.
Solution Approach 2:
The beam functions as a composite structure combining different wall thicknesses (thinner central portion with multi-sided cross-section and thicker end portions) to achieve optimal strength-to-weight ratio. The thinner central section reduces weight while the multi-sided geometry compensates for reduced thickness, and the thicker ends ensure proper connection strength.
Data Source
AI summary
Several different cross sections of beam having more than four sides are disclosed that may form a central portion of a beam having end portions that have four sides. The end portions of the beams may be received by frame rails. The central portion of the beam between the frame rails may be formed with more than four sides. The additional sides may be recessed beads or protruding ribs. Beams having arcuate recesses or arcuate ribs may be provided on the central portion of the beam. The end portions of the beams may extend outboard of the frame rails. The ribs or beads on the central portion of the beam may provide equivalent performance to four-sided beams having considerably thicker walls. Weight reduction is achieved because the central portion is made of a thinner material while retaining strength by forming beads or ribs in the central portion.